Drive shaft with inner joint type "star" (tripod joint)
1 - cuff collar; 2 - cuff clamp; 3 - bracket; 4 - hinge body; 5 - retaining ring; 6 - tripod hinge; 7 - cuff; 8 - clamp; 9 - counterweight only on the right side; 10 - cuff clamp; 11 - cuff collar; 12 - cuff; 13 - external hinge with a shaft. (If possible, do not disassemble and lubricate. Use the grease from the repair kit.)
Drive shaft with internal ball joint
1 - cuff collar; 2 - bracket; 3 - outer clip; 4 - retaining ring; 5 - inner clip; 6 - separator; 7 - balls; 8 - cuff clamp; 9 - cuff; 10 - cuff clamp; 11 - counterweight; Only on the right side:; 12 - cuff clamp; 13 - cuff; 14 - external hinge with a shaft; If possible, do not disassemble.
Depending on the model, drive shafts are installed, which differ in the internal joint: drive shafts with an internal ball joint are installed on cars up to 9/89, issue. and on the model "station wagon" with manual transmission. Driveshafts with tripod joints are installed on vehicles from 10/89, except for models "station wagon". All four-wheel drive vehicles have drive shafts with internal ball joints, in connection with the intermediate shaft for the right drive shaft.
Examination
1. Visually check the cuffs, replace the defective cuffs immediately. To replace the covers, the drive shaft must be removed and disassembled. Since the outer hinge must not be disassembled, to remove its cuff, it is necessary to remove the cuff of the inner hinge.
2. Clamp the removed drive shaft in a vice with gaskets and check the mobility of the hinges.
3. Stretch and compress the outer hinge by hand, it must not have any play.
4. The inner tripod joint should move along the shaft.
5. Try to rotate the inner joint on the shaft. It should not have appreciable radial play.
6. If the test reveals faults, the drive shaft should be replaced.
Drive shaft disassembly
1. Mark the edges of the joint collars on the shaft before removing them, this will facilitate installation.
2. Remove the cuff collars on the inner hinge using a screwdriver.
3. Move the joint collars on the shaft.
Drive shaft with internal tripod joint
1. Before removing the housing, mark the position in relation to the sprocket.
2. Mark with a punch the position of the shaft relative to the sprocket, so it must be installed in its original place.
3. Compress and remove the sprocket retaining ring with suitable pliers.
4. Knock the sprocket off the shaft with a hammer and brass rod, without hitting the rollers.
Drive shaft with internal ball joint
1. Before removing the shaft, mark its position relative to the outer race.
2. Pry off the locking clip with a flathead screwdriver. Remove inner hinge.
3. Compress the retaining ring of the inner race with suitable pliers and remove it. Mark the shaft with a center punch so that it can be installed in its original position.
4. Knock the inner race off the shaft with a hammer and brass rod.
5. If necessary, disassemble the inner race. To do this, insert a narrow screwdriver between the inner race and separator and squeeze out the balls.
6. Mark the position of the cage relative to the inner race. Rotate separator 30°and remove from inner race.
All drive shafts
1. Remove the inner joint collar from the shaft.
2. Right drive shaft: If equipped, loosen the counterweight clamp and remove the balancer.
Attention! Mark the position of the counterweight on the shaft so that it can be reinstalled.
3. If problems are found on the outer hinge: Remove the outer hinge collar through the side of the inner hinge, after loosening the collar clamps.
Attention! The outer hinge must not be disassembled.
4. Thoroughly wipe the internal cavities of the hinge, internal parts, flanges, caps and cuffs. Remove old grease with solvent or compressed air. If dirt has entered the hinge, wash it.
5. Check the working surfaces for wear, replace the joint if necessary.
Assembly
1. Replace cracked and defective cuffs. In any case, all the collars of the cuffs, as well as the retaining rings, should be replaced.
2. Lightly lubricate the surface of the shaft so that the cuffs slide better. In addition, wrap the splines of the shaft with plastic tape so that the seal is not damaged during installation.
3. Put on the cuff of the outer joint with clamps, do not fasten the clamps yet. Do not confuse the joint seals: Select the collar according to the outer diameter of the joint, the table applies to vehicles from 10/89 MY. (except models "station wagon").
Engine | diameter A, mm | diameter B, mm |
1.3 l. Diesel | 82,0 | 85,3 |
1.6 l | 85,9 | 80,8 |
1.9 L SOHC | 84,0/80,01 | 89,0 |
1.9L DOHC | 89,9 | 85,2 |
1 - left drive shaft
Attention! The mounting direction of the clamps corresponds to the forward rotation of the shaft, i.e. the bent end of the clamps must face in the direction of the shaft rotation.
4. Right drive shaft: If available, put on the counterweight, the fastening collar must lie in the groove of the drive shaft. If there is no groove, align the counterweight to the mark made during removal.
5. To put on a cuff of an internal hinge with collars.
Drive shaft with internal tripod joint
1. Put the sprocket on the drive shaft, making sure that the punch marks made when removing the center punch mark match. Drive the sprocket onto the shaft with a hammer and a brass rod. In this case, do not apply force, install the rod alternately at different points.
2. Insert a new circlip into the shaft groove.
3. Fill the cavities of the external hinge between the internal parts on both sides with special grease (black color). Make sure that as little lubricant as possible gets into the cuffs. A special lubricant is applied to the MAZDA seal repair kit. Distribute the entire amount of lubricant, approximately 80 g; 1.9L SOHC engine: 140g
4. Spread all the grease from the repair kit over the inner joint housing (yellow color). Amount of grease 130 g; Except RH 1.9L SOHC engine driveshaft: 220g.
5. Insert the sprocket into the housing in the same position as during removal and tighten the collar.
Drive shaft with internal ball joint
1. Assemble inner cage with balls and cage in reverse order of removal. The labels applied must match.
2. Put the inner race on the drive shaft, at the same time, the punch marks applied when removing the punch mark should match. Insert new retaining ring.
3. Insert the outer race of the hinge and insert new locking bracket.
4. Fill the cavities of the external hinge between the internal parts on both sides with special grease (black color) from a MAZDA repair kit. The amount of new grease compensates for the amount of grease removed. If all the old grease has been removed, use all the grease from the repair kit.
All drive shafts
1. Fix the cuffs on the large diameter with clamps. The cuffs must sit securely in the grooves of the shaft. Bend the clamps of the cuffs with a screwdriver and secure by bending the fasteners.
2. Move the cuffs on the small diameter to the mark or groove on the shaft. The cuffs in the installed state should not be stretched or compressed.
3. Slightly lift the cuff on the small diameter with a small screwdriver to compensate for the pressure. Then tighten the cuff collar and secure it.
4. Install the drive shaft.